Process for the synthesis of crystalline ceramic powders of perovskite compounds

Abstract: A process for the preparation of crystalline perovskite powders consisting essentially of primary particles uniform in nanometer or micrometer size and uniform and near spherical shape and of narrow size distribution, of the general formula A x (BO₃) y , wherein cation A is at least one metal selected from the group comprising Li⁺, Na⁺, K⁺, Mg²⁺, Ca²⁺, Sr²⁺, Ba²⁺ and La³⁺ and B in the anion (BO₃) is at least one metal selected from the group consisting of Ti⁴⁺, Zr⁴⁺, Sn⁴⁺, Hf⁴⁺, Nb⁵⁺ and Ta⁵⁺, x is equal to the valence of the anion (BO₃) and y is equal to the valence of cation (A), comprising contacting, under stirring, an aqueous solution (I) containing inorganic or organic salts or organometallic compounds of at least one metal A and of at least one metal B, the ratio (A)/(B) being around the stoichiometric value corresponding to the above general formula, with an aqueous basic solution (II) containing an inorganic or organic base in an amount at least above the stoichiometric amount corresponding to the above general formula, preheated to 70°-100°C, and performing the process at temperatures of from 70° to 100°C while maintaining the reaction mixture at constant OH⁻ concentration.

Description: FIELD OF THE INVENTION The present invention relates to a process for producing crystalline perovskite, A x (BO 3 ) y , ceramic powders consisting of submicron or nanosized dispersible primary particles of narrow size distributions and uniform, essentially spherical morphology. The powders may contain other secondary ingredients, such as dopants that alter electric properties, on the A and/or B sites. The A cation is selected from the group consisting of lithium, sodium, potassium, magnesium, calcium, strontium, barium, and lanthanum; and B in BO 3 is selected from the group consisting of titanium in the oxidation state 4, zirconium in the oxidation state 4, niobium in the oxidation state 5, tantalum in the oxidation state 5, tin in the oxidation state 4, and hafnium in the oxidation state 4. The powders may also contain other additives, such as binders, to enhance their sinterability and other properties. The powders have great usefulness in many applications including dielectric, piezoelectric, electrooptic, thermal sensors, and other ceramic industries. DESCRIPTION OF THE PRIOR ART The perovskite typified by BaTiO 3 has a cubic structure when treated above 135°C. Its lattice consists of a regular array of oxygen ions at the corners, a small tetravalent titanium ion in the center, and big divalent barium ions located at the face centers. The perovskite structure is distorted at low temperatures, where it exhibits tetragonal, orthorhombic, or rhombohedral symmetry. The transition temperature at which the crystal structure transforms from the distorted phase to the cubic phase is called the Curie temperature. Ferroelectric behaviour is caused by the shift in the position of the central cation, i.e., Ti ion in BaTiO 3 , which results in a displacement of the centers of positive and negative charges within the lattice and generates a spontaneous polarization. The electric properties of perovskites are significantly affected by this ferroelectric behaviour which contributes to useful dielectric, piezoelectric, and electrooptic properties. In recent years, electronic devices have become much smaller in size and higher in performance than ever before. This trend is also true in ferroelectric ceramics produced from the perovskite compounds. Intensive investigations have been made to improve the process for producing dielectric ceramics, such as molding and sintering methods. However, it seems necessary to improve the properties of the starting powders of perovskite compounds, in addition to the processes for the production of ceramic dielectrics, in order to obtain advanced superior products. In particular, pure perovskite powders consisting of uniform submicrometer particles having high crystallinity are desirable for good sinterability, dense packing, fine grained microstructure in sintered bodies, and high dielectric constant. Perovskite compounds are usually produced by mixing a carbonate or an oxide of at least one element selected from the group consiting of Mg, Ca, Sr, and Ba (A group elements), with an oxide of at least one element selected from the group consisting of Ti, Zr, Nb, Hf, and Sn (B group elements), calcining the mixture at temperatures not less than 1000°C, wet pulverizing, filtering and then drying the product. According to this method, the powders generated by calcination aggregate to cakes which are difficult to be pulverized to fine particles smaller than 1 µm even by wet pulverization using a trommel. In addition, the particles are irregular in shape. Therefore, conventional powders usually have to be sintered at temperatures of 1350°C or higher to produce dielectric ceramics having sufficient dielectric properties suitable for practical use. Another disadvantage of this method is the need for high melting temperatures and, hence, an expensive noble metal e.g. Pd, as an internal electrode material. Furthermore, the grain sizes in sintered bodies are usually in the range of 5 to 10 µm, which is far from the optimal grain size of 0.5 to 2 µm for high dielectric constant and volume efficiency. Worst of all, the batch-to-batch variation in this solid state reaction process makes the quality of the product unpredictable. Recent efforts in the preparation of perovskite compounds have been focused on liquid phase techniques, since solid state reaction described above could not yield uniform and small particles. Thus, according to USP 5,032,375, submicron barium titanate cystalline powder, polydispersed and having angular morphology, is obtained by first precipitating an amorphous powder by hydrolysis of titanium alcoholate in the presence of barium oxide, barium hydroxide, or barium alcoholate and an acid organic compound, then heating the powder under a stream of a gas to achieve crystallization. According to USP 5,009,876, barium titanate is produced by adding an aqueous solution of barium chloride to an aqueous solution of oxalic acid and titanium oxychloride at 20-60°C under stirring, to precipitate barium titanyl oxalate which is then calcined at 960-1200°C. According to USP 4,832,939, submicron barium titanate based powders having narrow size distributions are produced by heating up to 200°C an aqueous slurry of PbO and/or Ca(OH) 2 with an excess of Ti(OH) 4 , and after the addition of a solution of Ba(OH) 2 , the slurry is heated up to 225°C to precipitate the perovskite compounds. It was also reported in USP 4,643,984 that perovskite compounds with the general formula ABO 3 could be obtained using a three step procedure. The first step involved subjecting a mixture of A and B hydroxides to hydrothermal reaction in aqueous media. Next, an insolubilizing (precipitating) agent, such as carbon dioxide, was added to the reaction mixture in order to precipitate unreacted A element materials to adjust the A to B stoichiometry. This step was necessary due to the soluble nature of the A elements including lead, strontium, calcium, barium, and magnesium, under the conditions of the hydrothermal treatment. The mixture formed after the second step contained both a B-rich crystalline oxide phase, formed during the hydrothermal reaction and an A-rich non-crystalline, non-oxide phase, formed during the second step. Alternatively the product slurry of the hydrothermal reaction was first filtered and washed, and then added to an aqueous medium containing the supplemental A elements. The product stoichiometry could further be adjusted by adding an insolubilizing agent. The final step was to filter and wash the product to the desired A to B atomic ratio. This process was demonstrated in the preparation of compound containing the A elements listed above and the B elements including titanium, zirconium, hafnium, and tin. Several investigators have reported similar processes for producing perovskite compounds. The salts (e.g. carbonates) or in some cases hydroxides, of many of the A and B constituents are combined in an aqueous mixture. The mixture is adjusted to a basic pH by adding alkaline metal hydroxides or amonium hydroxide. This mixture is then reacted under hydrothermal conditions to produce crystalline perovskite compounds. The product slurry is cooled, filtered, and washed with water to remove impurities remaining from the salts and the pH adjusting chemicals. Examples of process which employ these procedures have been reported by Fuji Titan Kogyo Co. in the Japanese patent JP61031345, by Yonezawa, et al in the USP 3,963,630, and by Battelle Memorial Institute in the international publication WO 90/06291. The above prior art processes have many disavantages in that they involve several reaction steps, require calcination or reaction under high temperature and pressure to obtain crystalline powders, and need complicated post-treatment on the product powders in order to adjust the stoichiometry. EP-A-0150135 discloses a process for the preparation of barium-strontium titanate perovskite fine powders, uniform in size and having an average particle size of 500 Å, comprising preparing an aqueous solution containing a titanium, a barium and a strontium salt, adding an aqueous-base solution to adjust the pH to 14 and then reacting the mixture at a temperature of 100°C for 4 hours. The problem to be solved in the present invention resides in a process having the following essential features: to prepare uniform crystalline, essentially spherical particles during the reaction process without using any calcination process before sintering; to have available a simple one step reaction process having high production rate and at the same time reducing operation costs and units or steps; a process working at low temperatures and pressures and easily controlled reaction; a process giving high yields and high conversion of the starting material to the end product; very high rate (kinetic) of the reaction; a water-based system with no organic solvent involved, in order to eliminate pollution problems; efficient washing procedure requiring minimum amount of water; no post-treatment on the powders obtained in the process for adjusting the stoichiometry; perfect reproducibility; powders having superior dielectric, sintering and microstructure properties with respect to the prior art powders; excellent disperdibility of the powder during the tape-casting process; increased uniformity of the grain sizes in the sintered product; small grain sizes to increase volume efficiency; control of the dielectric constant vs. temperature, curve, to be either broad for the MLC capacitor application, or extremely sharp for the thermal sensor application. The solution to the above problem has been unexpectedly and surprisingly found by the process of the present invention to be described below. In particular, it has been found that the powders of the present invention have shown high a dielectric constant, which increases the volume efficiency of the product; they have a low sintering temperature, which reduces the cost of the electrode materials; they show small grain size, which increases the volume efficiency of the product. SUMMARY OF THE INVENTION We have now found a simple, single step, highly reproducible process, which operates at low temperatures and permits direct production, in very short time, with high yield, of finely dispersed crystalline perovskite powders uniform in nanometer or micrometer size, uniform and near spherical shape, without the need for calcination. On sintering these powders produce solids of near theoretical density with fine uniform grains of the order of 1-2 µm. Thus, the object of the present invention is a process for the preparation of crystalline perovskite compounds of predetermined average particle sizes and compositions, having improved electric properties, having a general formula, A x (BO 3 ) y , where A is primarily of the group lithium, sodium, potassium, strontium, and barium and B is primarily of the group titanium in the oxidation state 4, and niobium in the oxidation state 5, and wherein the A and/or B sites may have dopants that provide superior electric properties. The dopants D that are used in partial substitution of elements in group A may include calcium, magnesium, strontium, lanthanum and the dopants D' that are used in partial substitution of elements in group B include zirconium in the oxidation state 4, tantalum in the oxidation state 5, hafnium in the oxidation state 4. The powders so prepared have controlled particle size distributions and have reduced sintering temperatures. In principle, the process of the present invention involves the method as disclosed in claim 1. Crystalline perovskite compounds are produced in a few minutes, which are then purified by washing with water, and dried to the final products. Therefore, when barium and titanium are selected as the primary components, the perovskite has the general formula of BaTiO 3 , wherein the dopant for Ba and/or Ti sites may have values between 0 to 50% by moles. DETAILED DESCRIPTION OF THE INVENTION The object of the present invention is a process for the preparation of crystalline perovskite powders consisting essentially of primary particles uniform in micrometer size (0.15 to 0.40 µm average size), uniform and near spherical shape, of narrow size distribution, of the general formula A x (BO 3 ) y , wherein cation (A) is at least one metal selected from the group comprising Li + , Na + , K + , Mg 2+ , Ca 2+ , Sr 2+ , Ba 2+ and La 3+ and (B) in the anion (BO 3 ) as designated in the above formula is at least one metal selected from the group consisting of Ti 4+ , Zr 4+ , Sn 4+ , Hf 4+ , Nb 5+ and Ta 5+ , x is equal to the valence of the anion (BO 3 ) and y is equal to the valence of cation (A), comprising the steps disclosed in claim 1. The salts can be selected from halides, nitrates, acetates, perchlorates, oxalates, preferably chlorides, or organometallic compounds, such as alkoxides. The base can be selected from strong bases such as alkali and alkaline-earth metal hydroxides and ammonium hydroxide, preferably NaOH or KOH. The total concentration of the metal ions in solution (I) can range within wide limits, advantageously from 0.1 to 2.0 mol dm -3 , preferably from 0.5 to 1.2 mol dm -3 . The base concentration in solution (II) can range within wide limits, generally from 0.4 to 6 mol dm -3 , provided that the pH of the reaction mixture is maintained at about a constant level, around 14. In general the molar ratio of the metal ions in group (A) to those in group (B) in solution ranges from about 0.8 to 1.2. The reaction mixture can be maintained at a pH of about 14 by addition of a concentrated base solution during the reaction as needed. The process of the present invention is performed by the technique known as "controlled double jet precipitation" referred to herein as CDJP. According to the CDJP, the aqueous solution (I) and aqueous solution (II) are separately and simultaneously injected, using metering pumps, into a CDJP reactor containing a stirred aqueous base solution, of pH of about 14, preheated to 70-100°C. The flow rate of solution (I) is maintained constant, while the base solution (II) is injected at such a flow rate, depending on the flow rate of solution (I), that the pH of the reaction mixture is maintained constant at about 14 and monitored by a pH meter, using a temperature sensitive glass electrode, during the entire operation performed at 70-100°C. The reaction temperature is kept constant by a temperature controlled circulator. The reaction mixture is kept stirred, preferably from about 400 to 700 rpm with a propeller during the entire operation. In the CDJP method, the flow rates of the reactant solutions (I) and (II) can be varied within a wide range from 5 to 40 cm 3 min -1 , depending on the concentrations of the reactants in the stock solutions and the pH at which the reaction mixture has to be maintained during the reaction. In the preparation of perovskites by the controlled double-jet precipitation (CDJP) technique, as described, e.g. in the case of preparation of Sr-doped BaTiO 3 , two stock solutions, i.e. (1) (II) NaOH solution and (2) (I) a solution containing all the necessary metal salts, for example, BaCl 2 , SrCl 2 , and TiCl 4 , are introduced into the reactor simultaneously to form particles, as described e.g. in Example 15 below. A variation of the double-jet precipitation (CDJP) is the controlled triple-jet precipitation (CTJP) technique. According to CTJP, three stock solutions, instead of two as in the CDJP, are separately injected into the reactor. Thus, in addition to solutions (I) and (II) there is used a solution (III) containing a salt of the same element B contained in solution (I) and a salt of a dopant D selected from Ca 2+ , Mg 2+ , Sr 2+ , and La 3+ or a salt of the same element A contained in solution (I) and a salt of a dopant D 1 selected from Zr 4+ , Sn 4+ , Hf 4+ , Nb 5+ , and Ta 5+ , D being different from A, and D' from B. The three solutions (I), (II), and (III) can be simultaneously injected at constant flow rates into the reactor (method a) or combinations of two are injected sequentially at a given time, i.e. by first simultaneously injecting solutions (I) and (II), followed by simultaneous injection of solutions (II) and (III) (method b), or first simultaneously injecting solutions (II) and (III), followed by simultaneous injection of solutions (I) and (II) (method c). In case e.g. of preparation of Sr-doped BaTiO 3 , three stock solutions, instead of two (as in the CDJP), are introduced into the reactor. These solutions are, for example, (1) a NaOH solution, (2) a solution containing BaCl 2 and TiCl 4 , and (3) a solution containing SrCl 2 and TiCl 4 . These three solutions can be introduced as follows: Method (a) all three are introduced simultaneously by jets at constant flow rates; Method (b) combinations of two are added at a given time in sequence, i.e. first solutions (1) (NaOH) and (2) are introduced simultaneously at constant flow rates for a desired period of time, aged, e.g., for 5 min., followed by simultaneous introduction of solutions (1) (NaOH) and (3) for some time, and finally aged, e.g., for 5 min., or Method (c) the same procedure as in (b) except first are introduced solutions (1) and (3), followed by solutions (1) and (2). The specific examples using the CTJP technique are given below. In general the sharp curve of dielectric constant vs. temperature has been obtained from the powders produced by the CDJP technique (see e.g. Fig. 8), in case of Sr-doped BaTiO 3 . Extremely sharp curves, such as the one in Figure 8, are difficult to obtain from the powders produced by other existing processes. The dielectric properties can be altered by the kind and concentration of the dopant. For example the broad curves are obtained with the use of Ca as dopants. Another aspect of the present invention is the production of doped perovskites. To achieve doped solids the stock solution (I) also contains desired, usually minor, amount of at least one doping metal element. For instance, in the case of barium titanate, part of Ba is substituted with at least one doping element D, where D being selected from Ca, Mg, Sr and La, and/or part of Ti is substituted with at least one doping element D 1 , where D 1 being selected from Zr, Sn, Nb, Ta and Hf. The doping contents can range from 0 to 50%, preferably from 5 to 25% by moles. Another advantage of the present invention is that the exact composition and the average size of the resulting particles can be varied, within a reasonable range, by adjusting the concentrations of the stock solutions, the pH of the reaction mixture during the process, the flow rates of the injected solutions, the reaction temperature, and the reaction time. In addition to these operation parameters, the average size can also be controlled by the addition of natural or synthetic polymers or surfactants such as gelatin, dextrans, dextrins, polyvinyl alcohol, polyethylene glycol, and polyvinylpyrrolidone, in the amounts varying from 0.01 to 2% by weight on the reaction mixture. At the completion of the reaction, the precipitated particles of crystalline perovskite compounds are separated from the mother liquor by decanting and centrifugation, or by filtration, and purified by washing with water and, finally, dried, preferably from 90° to 110°C. Spray or freeze drying can be used, if desired. The processes of the present invention are rapid, require low temperatures, and the yields are high, substantially quantitative. Crystalline particles of perovskite compounds can be produced in less than 5 min, at temperatures which need not to exceed 100°C, without using a pressurized reactor. The processes of the present invention, however, if desired, can also be performed at higher temperatures up to 250°C, by using pressurized reactors. The solid crystalline particles obtained by the present processes can be sintered to high densities at temperatures 100 to 300°C below the sintering temperatures of standard ball-milled and calcined powders, to produce ceramics exhibiting uniform microstructures, homogeneous chemical compositions, and high dielectric constants as high as 25,000 depending on the composition. In order to improve the body integrity of the sintered pellets, it may be useful to incorporate a known binder in the green bodies. The binder may be selected from polyvinyl alcohol, polyvinylbutyral, and polyethylene glycol, in the amount, preferably of 0.5 to 4.0% by weight, in the green pellets. Barium titanate pellets of 98% theoretical density (6.01 g cm -3 ) were obtained when sintered at 1200°C, and 99 to 100% theoretical density was achieved when sintered at 1250°C. In contrast, the commercial barium titanate powders only sinter to about 85% theoretical density at 1200°C. The powders obtained by the processes of the present invention were characterized in terms of chemical composition, crystallinity, morphology, and particle size distribution by using the following methods. Chemical Analysis The chemical compositions were determined by atomic absorption spectrophotometry, induction coupled plasma (ICP) technique, colorimetry, and gravimetric or titration analyses. For barium titanate powders, approximately one gram of the dry solid was dissolved in 25 cm 3 of hot concentrated sulfuric acid, then diluted with cold water and left standing for 12 hours. The resulting white precipitate was separated from the mother liquor by filtration using non-ash filter paper, placed in a crucible, and then burnt at 800°C for 1 hour. The white powder was weighed as BaSO 4 . The titanium content was then determined by titration technique. To the filtrate, 30 cm 3 of concentrated HCl was added, heated to 75°C, and 3 g of high purity aluminum was admixed until dissolved. After cooling to below 50°C, 5 cm 3 of saturated NH 4 SCN solution was added as an indicator, and then the entire system was titrated with 0.1 mol dm -3 FeNH 4 (SO 4 ) 2 solution. Crystallinity The crystal structure was determined by X-ray powder diffraction (XRD) analysis with a CuKα1 X-ray source was employed for this purpose. Morphology The morphology of the powders was elucidated by transmission (TEM) and scanning electron microscopies (SEM). Particle Size Distribution The particle size distributions were determined from electron micrographs using a particle size analyzer. Sintering Conditions The powders were further sintered and the dielectric constants were determined on the sintered pellets by using the following conditions and methods. To make a green pellet, about 1 g of powder was placed in a cylindrical die and uniaxially pressed under 25 MPa using a Carver laboratory hydraulic press. The pellet was placed in a latex balloon, the air from which was then evacuated, and the content was isostatically compressed under 340 MPa in the oil chamber of a Fluitron cold isostatic press unit. Finally, the green pellet was removed, weighed, and its dimensions measured using vernier calipers. The resulting green density was calculated according to the weight and dimensions measured, and compared to the theoretical density. The green pellets were subsequently sintered in a high temperature furnace under air at different temperatures for 60 min using a heating/cooling rate of 8°C min -1 . The sintered densities were measured according to the ASTM (C373-55T) standard procedure based on the Archimedes principle. Dielectric Constant To determine the dielectric constants, a sintered pellet was coated with gold film on both sides, placed between two parallel copper electrodes, and the capacitances were then evaluated at frequencies of 100 Hz, 1kHz, 10 kHz, and 100 kHz at temperatures ranging from -55 to 145°C. The dielectric constants were calculated from the capacitances so obtained. The Y5V capacitor as reported below, is characterized by the maximum dielectric constant between 10.000 and 15.000. The deviation of the dielectric constant at temperatures from -30 to 85°C, from that at 25°C, should fall between -82% and +22%. The specifications for a Z5U-capacitor (see below) are: the maximum dielectric constant is between 4.000 to 12.000; and the deviation of the dielectric constant at temperatures from 10 to 85°C, from that at 25°C, should fall between -56% and +22%. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1. Scanning electron micrograph (SEM) of the BaTiO 3 particles obtained as described in Example 1. Figure 2. SEM picture of the microstructure of the pellet containing the powder shown in Figure 1, sintered at 1200°C for 1 hour. Figure 3. Plot of the dielectric constant K vs. temperature for the same pellet described in Figure 2. Figure 4. SEM picture of the BaTiO 3 particles obtained as described in Example 11. Figure 5. SEM picture of the BaTiO 3 particles obtained as described in Example 12. Figure 6. SEM picture of the Zr-doped BaTiO 3 particles obtained as described in Example 13. Figure 7. XRD pattern of the powder of Example 1. Figure 8. The plot as in Fig. 3 for Example 15. The following examples are given for illustration purposes. EXAMPLE 1 : Barium titanate by the CDJP process An aqueous solution containing a mixture of BaCl 2 and TiCl 4 and a 6 mol dm -3 NaOH solution were simultaneously introduced, at constant flow rates of 12 and 8 cm 3 min -1 , respectively, into a 330 cm 3 CDJP reactor containing 100 cm 3 stirred 1 mol dm -3 NaOH solution preheated at 88°C. The temperature dropped to 83-85°C and then was maintained constant at 85°C. The total concentration of the BaCl 2 + TiCl 4 solution was 1 mol dm -3 , while the molar ratio [BaCl 2 ]/[TiCl 4 ] was kept at 1.07. The introduction of the BaCl 2 + TiCl 4 and NaOH solutions lasted 8 min, subsequently followed by aging at 85°C under stirring for 3 min. The precipitation of colloidal crystalline particles of BaTiO 3 took place instantaneously. The resulting solid settled rapidly and the supernatant solution was decanted. The so concentrated suspension was then centrifuged at 500 rpm, the remaining supernatant solution was again decanted and the solids were washed twice with boiling deionized water and once with cold deionized water with agitation in an ultrasonic bath. The purified powder was separated by centrifugation and dried at 100°C. The so obtained powder was proved, by chemical analysis, to be pure barium titanate (BaTiO 3 ) with a molar ratio [Ba]/[Ti] of 1.00 in the solid. The scanning electron micrograph (SEM) in Figure 1 shows that the particles are substantially spherical with an average size of 0.2 µm. The X-ray powder diffraction (XRD) pattern (Fig. 7) indicated that the powder to be well crystalline, pure phase BaTiO 3 . The chemical analysis of the supernatant solution at the completion of the process showed no presence of titanium ions. Thus, the entire initial amount was converted to BaTiO 3 . The powder was pressed into pellets and sintered at different temperatures for 1 hour, according to the procedure previously described, and the sintered densities were compared to those of a commercial barium titanate powder (supplied by Chon International Co, Ltd., Seoul, Korea): Sample Sintered densities (% theoretical) 1100°C 1150°C 1200°C 1250°C Commercial 68.5 73.9 85.7 98.9 Prepared according to Example 1 - 79.8 97.4 99.8 Fig. 2 shows the scanning electron micrograph of the microstructure of the pellet, containing the powder produced in this example, sintered at 1200°C for 1 hour. The grains are small and uniform with an average size of 1.4 µm. The dielectric constants of the same pellet were measured as a function of temperature, and the results are shown in Figure 3. The sample has a Curie temperature of 120°C at which the dielectric constant peaks at 9,200. At 20°C, the sample has a dielectric constant of 5,000, which is superior to any reported values for pure BaTiO 3 . EXAMPLE 2: Barium titanate by the CDJP process A series of CDJP experiments were carried out in a 330 cm 3 CDJP reactor to examine the effect of the flow rate of NaOH solution. An aqueous solution containing a mixture of BaCl 2 and TiCl 4 and a 6 mol dm -3 NaOH solution were simultaneously introduced, at constant flow rates, into the CDJP reactor containing 100 cm 3 stirred 1 mol dm -3 NaOH solution preheated to 88°C. The total concentration of the BaCl 2 + TiCl 4 solution was 1 mol dm -3 , while the molar ratio [BaCl 2 ]/[TiCl 4 ] was kept at 1.07. The flow rate of the BaCl 2 + TiCl 4 solution was kept constant at 12 cm 3 min -1 , while the flow rate of the NaOH solution was varied from 5 to 14 cm 3 min -1 . The reaction temperature was kept at 85°C. The introduction of the BaCl 2 + TiCl 4 and NaOH solutions lasted 8 minutes, subsequently followed by aging at 85°C under stirring for 3 minutes. The obtained dispersions, treated as in Example 1, gave powders consisting of particles which were well crystalline and spherical in shape. The particle size increased, from 0.15 to 0.28 µm, with decreasing flow rate from 14 to 5 cm 3 min -1 . EXAMPLE 3: Barium titanate by the CDJP process This example illustrates the effect of increased reaction volume. An aqueous solution containing a mixture of BaCl 2 and TiCl 4 and a 6 mol dm -3 NaOH solution were simultaneously introduced, at constant flow rates of 24 and 16 cm 3 min -1 , respectively, into a 900 cm 3 CDJP reactor containing 200 cm 3 stirred 1 mol dm -3 NaOH solution preheated at 88°C. The temperature dropped to 83-85°C and then was maintained constant at 85°C. The total concentration of the BaCl 2 + TiCl 4 solution was 1 mol dm -3 , while the molar ratio [BaCl 2 ]/[TiCl 4 ] was kept at 1.07. The introduction of the BaCl 2 + TiCl 4 and NaOH solutions lasted 8 min, subsequently followed by aging at 85°C under stirring for 3 min. The resulting dispersion was treated the same as in Example 1. Barium titanate particles so obtained had the same charateristics as those in Example 1. This process yielded twice the weight of the solid as compared to Example 1. EXAMPLE 4: Barium titanate by the CDJP process The experiment, as described in Example 3, was repeated using the same procedure except that the flow rates of the NaOH and BaCl 2 + TiCl 4 stock solutions were 24 and 36 cm 3 min -1 , respectively. The so obtained suspension was treated the same as in Example 1. The resulting solid had the same characteristics as that obtained in Example 3, and the weight of the solid produced was three times larger than obtained in Example 1. EXAMPLE 5 : Barium titanate by the CDJP process This example is offered to show that BaTiO 3 particles of different sizes can be obtained by altering the experimental conditions. An aqueous solution containing a mixture of BaCl 2 and TiCl 4 and a 6 mol dm -3 NaOH solution were simultaneously introduced, at constant flow rates of 12 and 8 cm 3 min -1 , respectively, into a 900 cm 3 CDJP reactor containing 200 cm 3 stirred 1 mol dm -3 NaOH solution preheated at 88°C. The temperature dropped to 83-85°C and then was maintained constant at 85°C. The total concentration of the BaCl 2 + TiCl 4 solution was 1 mol dm -3 , while the molar ratio [BaCl 2 ]/[TiCl 4 ] was kept at 1.07. The introduction of the BaCl 2 + TiCl 4 and NaOH solutions lasted 30 min, subsequently followed by aging at 85°C under stirring for 3 min. The final volume of the resulting suspension was 800 cm 3 . The so obtained particles were well crystalline and had an average particle size of 0.4 µm. EXAMPLE 6: Barium titanate by the CDJP process Another experiment was conducted using the same conditions as in Example 5, except the starting volume of the 1 mol dm -3 NaOH solution was reduced to 100 cm 3 . The average particle size of the resulting solid was 0.3 µm, while the other charateristics were the same as those obtained in Example 5. EXAMPLE 7: Barium titanate by the CDJP process This example shows the result when NaOH is substituted by KOH. An aqueous solution containing a mixture of BaCl 2 and TiCl 4 was introduced, at a constant flow rate of 10 cm 3 min -1 , into a 330 cm 3 CDJP reactor containing 100 cm 3 stirred 1 mol dm -3 KOH solution preheated at 88°C. The total concentration of the BaCl 2 + TiCl 4 solution was 1 mol dm -3 , while the molar ratio [BaCl 2 ]/[TiCl 4 ] was kept at 1.07. The introduction of the BaCl 2 + TiCl 4 solution lasted 7 minutes, subsequently followed by aging at 85°C under stirring for 3 minutes. The pH of the reaction mixture was monitored and automatically adjusted by addition of a concentrated KOH solution (6 mol dm -3 ) through a metering pump to keep it constant at a value of 14. The precipitated solid was purified and dried as previously described in Example 1. The so obtained powder shows the same characteristics as those of the powder obtained according to Example 1. EXAMPLE 8: Barium titanate by the CDJP process Example 7 was repeated, but instead of continuously adjusting the pH, which involved a change in the flow rate of the added 6 mol dm -3 KOH solution, the KOH solution was introduced into the reaction mixture at a constant flow rate of 8 cm 3 min -1 and the BaCl 2 + TiCl 4 stock solution at 12 cm 3 min -1 . The so obtained solid showed the same characteristics as the powder produced according to Example 7. EXAMPLE 9: Barium titanate by the CDJP process Experiments were conducted according to the procedures described in Example 7, except that the flow rate of the BaCl 2 + TiCl 4 stock solution was varied from 6 to 16.7 cm 3 min -1 . The resulting particles were treated the same as in Example 1. The results showed that the average particle size depended little on the rate of the addition of the metal salts solution. The characteristics of the solids were the same as those of the powder in Example 7. EXAMPLE 10: Barium titanate by the CDJP process The experiments were carried out to investigate the effect of the pH on the particle formation using the conditions described in Example 7. The pH of the reaction mixture was controlled at different values ranging from 13.5 to 14.0. The results showed that the dispersity of the powders was rather sensitive to the pH. The XRD patterns indicated that the particles were only partially crystalline at pH < 13.6 (or equivalent to 0.42 mol dm -3 OH - ), but had clearly crystalline properties of pure BaTiO 3 at pH values higher than 13.6. EXAMPLE 11: Barium titanate by the CDJP process The experimental conditions were the same as in Example 7, except that 0.1% by weight of β-cyclodextrin was added in the 100 cm 3 of 1 mol dm -3 KOH solution in the CDJP reactor. The resulting suspension was treated the same as in Example 1. The so obtained solid was well crystalline, consisting of finely dispersed uniform spherical particles, yet smaller in size with an average diameter of 70 nm as shown in Figure 4. EXAMPLE 12: Strontium titanate by the CDJP process An aqueous solution containing a mixture of SrCl 2 and TiCl 4 and a 6 mol dm -3 NaOH solution were simultaneously introduced, at constant flow rates of 12 and 8 cm 3 min -1 , respectively, into a 330 cm 3 CDJP reactor containing 100 cm 3 stirred 1 mol dm -3 NaOH solution preheated at 88°C. The temperature dropped to 83-85°C and then was maintained constant at 85°C. The total concentration of the SrCl 2 + TiCl 4 solution was 1 mol dm -3 , while the molar ratio [SrCl 2 ]/[TiCl 4 ] was kept at 1.07. The introduction of the SrCl 2 + TiCl 4 and NaOH solutions lasted 8 min. subsequently followed by aging at 85°C under stirring for 3 min. The resulting suspension was treated the same as in Example 1. The so obtained SrTiO 3 particles are rather uniform spheres of good cystallinity. EXAMPLE 13 : Zirconium doped barium titanate by the CDJP process To prepare Zr doped BaTiO 3 , a reactant solution containing 0.517 mol dm -3 BaCl 2 , 0.386 mol dm -3 TiCl 4 , and 0.097 mol dm -3 ZrCl 4 (which corresponded to a molar ratio [BaCl 2 ]/([TiCl 4 ]+[ZrCl 4 ]) of 1.07 and [TiCl 4 ]/[ZrCl 4 ] = 4) was used. A 6 mol dm -3 NaOH solution was used to maintain the pH of the reaction mixture at 14. The flow rates of the BaCl 2 +TiCl 4 +ZrCl 4 and NaOH stock solutions were 12 and 8 cm 3 min -1 , respectively. The other experimental procedures were the same as described in Example 1. The so prepared Zr-doped BaTiO 3 particles appeared to be spherical, uniform in size, and well crystalline as depicted in Figure 6 with an average diameter of 0.2 µm. The XRD pattern indicates a change in the crystal lattice due to the incorporation of Zr. The results from chemical analysis showed the incorporation of Zr to be quantitative with a molar ratio [Ti]/[Zr] of 4, corresponding to a Zr doping content of 20% in the solid. EXAMPLE 14: Zirconium doped barium titanate by the CDJP process This example illustrates the preparation of Zr-doped BaTiO 3 with different dopant contents. Experiments were carried out using the same experimental conditions as in Example 13, except that the reactants concentrations in the BaCl 2 + TiCl 4 + ZrCl 4 stock solution varied according to: Zr dopant content solid (%) Concentration of the reactants (mol dm -3 ) BaCl 2 ZrCl 4 TiCl 4 10 0.517 0.048 0.435 17 0.517 0.072 0.411 24 0.517 0.116 0.367 30 0.517 0.145 0.338 The so obtained powders consisted of well crystalline, uniform spherical particles, similar to those obtained in Example 13. EXAMPLE 14A Example 14 was repeated by changing the concentrations to prepare a 20% Zr-doped BaTiO 3 . The dielectric data of the 20% Zr-doped BaTiO 3 powder, sintered at 1275°C showed that the Curie temperature is shifted to 50°C (compared with Fig. 3) and the curve is broad enough to meet the requirements for Y5V-capacitor application. EXAMPLE 15: Strontium doped barium titanate by the CDJP process This example illustrates the preparation of Sr doped barium titanate particles. For this purpose, the experimental conditions are the same as in Example 13, except that the reactants in the stock solution had the following concentrations: Sr dopant content in solid (%) Concentrations of the reactants (mol dm -3 ) BaCl 2 SrCl 2 TiCl 4 10 0.465 0.052 0.483 20 0.414 0.103 0.483 30 0.362 0.155 0.483 The so prepared Sr-doped particles were substantially spherical and well crystalline, similar to those of Example 13. In Fig. 8 it is reported the curve of dielectric constant vs. temperature of the powders doped with 30% by weight of Sr when sintered at 1300°C. The Curie temperature is shifted to 37°C compared to Fig. 3. The curve is very sharp and this powder can be used for thermal sensor applications. EXAMPLE 16: Calcium doped barium titanate by the CDJP process This example illustrates the preparation of Ca doped barium titanate particles. For this purpose, the experimental conditions were the same as in Example 13, except that the reactants in the stock solution had the following concentrations: Ca dopant content in solid (%) Concentrations of the reactants (mol dm -3 ) BaCl 2 CaCl 2 TiCl 4 10 0.465 0.052 0.483 20 0.414 0.103 0.483 30 0.362 0.155 0.483 The so prepared Ca-doped particles were substantially spherical and well crystalline, similar to those of Example 13. EXAMPLE 17: Calcium and Zirconium doped barium titanate by the CDJP process The experimental conditions were the same as in Example 13, except that the reactant solution contained 0.507 mol dm -3 BaCl 2 , 0.010 mol dm -3 CaCl 2 , 0.386 mol dm -3 TiCl 4 and 0.097 mol dm -3 ZrCl 4 , which corresponded to molar ratios ([BaCl 2 ]+[CaCl 2 ])/([TiCl 4 ]+[ZrCl 4 ]), [BaCl 2 ]/[CaCl 2 ], and [TiCl 4 ]/[ZrCl 4 ] of 1.07, 49 and 4, respectively. The so obtained mixed Ca and Zr doped BaTiO 3 particles were substantially spherical and well crystalline. EXAMPLE 17A Example 17 was repeated by changing the concentration of CaCl 2 into 0.0052 mol dm -3 , to obtain BaTiO 3 doped with 1% Ca and 20% Zr. The dielectric data showed that the curve is broad enough to meet the characteristics of Z5U-capacitor when sintered at 1300°C. EXAMPLE 18: Potassium niobate by the CDJP process An aqueous solution containing 0.20 mol dm -3 KCl, 0.185 mol dm -3 NbCl 5 and 0.04 mol dm -3 H 2 O 2 and a separate 6 mol dm -3 KOH solution were simultaneously introduced, at constant flow rates under stirring into a 300 cm 3 reactor containing 1 mol dm -3 KOH solution preheated at 90°C. The flow rates of the KCl + NbCl 5 + H 2 O 2 and KOH stock solution were 12 and 8 cm 3 min -1 , respectively. The reaction time was 8 min followed by 5 min of aging at 90°C. The resulting dispersion was washed once with boiling water, and once with cooled water and dried at 100°C. The so obtained particles are uniform, spherical, nanoscaled in size with an average diameter of 17 nm. The XRD pattern shows that the particles to be crystalline potassium niobate, KNbO 3 . EXAMPLE 19 Sr-doped barium titanate by the CTJP technique (method (a) of the description) The solutions are the following: (1) a 6 mol dm -3 NaOH solution, (2) a solution containing BaCl 2 and TiCl 4 , and (3) a solution containing TiCl 4 and SrCl 2 . The total concentrations of [BaCl 2 ]+[TiCl 4 ] and [SrCl 2 ]+[TiCl 4 ] are both, 1.0 mol dm -3 and the molar ratios [BaCl 2 ]/[TiCl 4 ] and [SrCl 2 ]/[TiCl 4 ] are both, 1.07. The reaction temperature is 85°C. These three solutions were introduced as follows: (a) all three are introduced simultaneously by jets at constant flow rates for 8 min., followed by aging for 5 min. The apparatus is the one of Example 13. According to the CTJP technique (a) described above, solutions 1, 2, and 3 are introduced into the reactor simultaneously at constant flow rates of 8, 9.6 and 2.4 cm 3 min -1 , respectively, for 8 min., followed by aging for 5 min. This system corresponds to 20% Sr-doped barium titanate. Uniform spherical particles of good single-phase crystallinity were produced, similar to those obtained using the CDJP technique. EXAMPLE 20 Sr-doped barium titanate by the CTJP technique (method (b) of the description) The solutions (1), (2), (3) are the same as in Example 19; and the reactor is the same, but the introduction of solutions into the reactor is the following (method b): combinations of two are added at a given time in sequence, i.e., first solutions (1) (NaOH) and (2) are introduced simultaneously at constant flow rates for a desired period of time, aged for 5 min., followed by simultaneous introduction of solutions (1) (NaOH) and (3) for some time, and finally aged for 5 min. According to the CTJP technique (b), solutions (1) and (2) are introduced into the reactor simultaneously at constant flow rates of 8 and 12 cm 3 min -1 , respectively, for 5 min., and aged for 5 min. Then, the solutions (1) and (3) are subsequently introduced at constant flow rates of 8 and 12 cm 3 min -1 , respectively, for 1, 2, 3, or 4 min., followed by aging for 5 min. The resulting dispersions contain spheres of good crystallinity but bimodal distributions, which are mixtures of BaTiO 3 and SrTiO 3 according to the XRD patterns. EXAMPLE 21 Sr-doped barium titanate by the CTJP technique (Method (c) of the description). The solutions (1), (2), (3) are the same as in Example 19 and the apparatus for the reaction is the same. Method (c) is the same procedure as in (b) of Example 20 except first are introduced solutions (1) and (3) followed by solutions (1) and (2). The specific examples using the CTJP technique are given as follows: According to the CTJP technique (c), the solutions (1) and (3) are introduced into the reactor, at constant flow rates of 8 and 12 cm 3 min -1 , respectively, for 1, 2, 3 or 4 min., followed by aging for 5 min. Then, the solutions (1) and (2) are subsequently introduced simultaneously at constant flow rates of 8 and 12 cm 3 min -1 , respectively, for 5 min., followed by aging for 5 min. The powders so obtained contain mixtures of crystalline BaTiO 3 and SrTiO 3 of bimodal distributions. The dielectric data of the powder so obtained, sintered at 1250°C, showed that the Curie temperature is shifted to 20°C, with respect to Fig. 3 of Example 1. The curve is broad enough to meet the requirements for Y5V-capacitor application. EXAMPLE 22 : Zr-doped barium titanate by the CDJP process Example 13 in the patent application was repeated using the same experimental procedures and conditions, except the molar ratio [BaCl 2 ]/([TiCl 4 ]+[ZrCl 4 ]) = 1.103. The corresponding concentrations of BaCl 2 , TiCl 4 , and ZrCl 4 in the reactant solution were 0.525, 0.380 and 0.095 mol dm -3 , respectively. The resulting powder was sintered at 1275°C for 2 h. The curve of dielectric constant vs temperature of the sintered powder meets the specification of Y5V-MLC capacitor application. EXAMPLE 23: Zr-doped barium titanate by the CDJP process The same powder described in Example 22 was sintered at 1300°C for 2 h. The curve of dielectric constant vs temperature of the sintered powder is sharper than that of Fig. 8 and is good for thermal sensor application. EXAMPLE 24 : Sr and Zr-doped barium titanate by the CDJP process Example 13 in the patent application was repeated using the same procedure and conditions, except that the reactant solution contained SrCl 2 besides BaCl 2 , TiCl 4 , and ZrCl 4 and the molar ratios ([BaCl 2 ]+[SrCl 2 ])/([TiCl 4 ]+[ZrCl 4 ]) = 1.077, [SrCl 2 ]/([BaCl 2 ]+[SrCl 2 ]) = 0.05 and [ZrCl 4 ]/([TiCl 4 ]+[ZrCl 4 ]) = 0.15. The corresponding concentrations of BaCl 2 , SrCl 2 , TiCl 4 , and ZrCl 4 in the reactant solution were 0.493, 0.026, 0.409 and 0.072 mol dm -3 , respectively. The resulting powder was sintered at 1350°C for 2 h. The curve of dielectric constant vs temperature of the sintered powder is sharper than that of Fig. 8 and is good for thermal sensor application.

Claims: A process for the preparation of crystalline perovskite powders consisting essentially of near spherical primary particles uniform in size and having an average size from 0.15 to 0.4 micrometers of general A x (BO 3 ) y , wherein cation (A) is at least one metal selected from the group comprising Li + , Na + , K + , Mg 2+ , Ca 2+ , Sr 2+ , Ba 2+ and La 3+ and (B) in the anion (BO 3 ) is at least one metal selected from the group consisting of Ti 4+ , Zr 4+ , Sn 4+ , Hf 4+ , Nb 5+ and Ta 5+ , x is equal to the valence of the anion (BO 3 ) and y is equal to the valence of the cation (A), comprising separately and simultaneously injecting into a reactor containing a stirred aqueous base solution of pH about 14, preheated to 70°-100°C, an aqueous solution (I) containing inorganic or organic salts or organometallic compounds of at least one metal A and of at least one metal B, the ratio A/B being around the stoichiometric value corresponding to the above general formula, and an aqueous basic solution (II) containing an inorganic or organic base in an amount at least above the stoichiometric value corresponding to the above general formula, by maintaining constant the flow rate of solution (I) and injecting the base solution (II) at such flow rate, depending on the flow rate of solution (I), said flow rate of solution (I) and (II) varying from 5 to 40 cm 3 . min -1 , so that the pH of the reaction mixture is maintained constant at about 14 while the process is performed at 70°C-100°C with a reaction time of 30 minutes or less. A process according to claim 1, in which the total concentration of metal ions in solution (I) ranges from 0.1 to 2.0 mol dm -3 , preferably from 0.5 to 1.2 mol dm -3 , the molar ratio A/B ranges from 0.8 to 1.2 and the base concentration in solution (II) ranges from 0.4 to 6 mol dm -3 . A process according to claim 1, in which the salts are selected from halides, nitrates, acetates, perchlorates, oxalates and alkoxides and the base is selected from alkaline or alkaline-earth metal hydroxides and ammonium hydroxide. A process according to claim 3, in which the salts are chlorides and the base is NaOH or KOH. A process according to claim 1, in which A is selected from Li + , Na + , K + , Mg 2+ , Ca 2+ , Sr 2+ and Ba 2+ optionally substituted with from 0 to 50% of at least one dopant D of the group Ca 2+ , Mg 2+ , Sr 2+ and La 3+ and B is selected from Ti 4+ , and Nb 5+ optionally substituted with at least one dopant D' of the group Zr 4+ , Sn 4+ , Hf 4+ , Nb 5+ and Ta 5+ , with the condition that D being different from A, and D 1 from B. A process according to claim 1 modified in such a way that besides solutions (I) and (II) there is used a solution (III) containing a salt of the same element B contained in solution (I) and a salt of a dopant D or a salt of the same element A contained in solution (I) and a salt of a dopant D', D being selected from Ca 2+ , Mg 2+ , Sr 2+ and La 3+ , D' being selected from Zr 4+ , Sn 4+ , Hf 4+ , Nb 5+ and Ta 5+ , D being different from A and D' from B, and wherein said three solutions are simultaneously injected into a reactor or combinations of two are injected sequentially at given time into the reactor.

Inventors: HER YIE-SHEIN, MATIJEVIC EGON, HER, YIE-SHEIN, MATIJEVIC, EGON
Applicants: CHON INT CO LTD, CHON INTERNATIONAL CO. LTD.
Application year: 1994
Main classification: C01G1
IPC codes: C01G27, C01G19, C01G35, C01B13, C01G25, C01G33, C04B35, C01F17, C01G23